Understanding the 5 Most Common Types of Industrial Mixers

Across many industries, industrial mixers play an essential role. From the food and beverage industry to pharmaceuticals, cosmetics, and adhesives, these mixers facilitate the blending and mixing of various materials to ensure consistency, quality, and efficiency in production. However, there are several types of industrial mixers to choose from. 

In this blog, we’ll dive into the most common types of industrial mixers and what to consider before making your decision.

5 Types of Industrial Mixers

Industrial mixers are pivotal to ensure consistency, enhance quality, and facilitate reactions. There are 5 common types of industrial mixers. 

1. Batch mixers
2. Continuous mixers
3. High-shear mixers
4. Low-shear mixers
5. Multi-shaft mixers
   
   

1. Batch Mixers

Batch mixers are the most commonly used type of industrial mixer. They work by combining all the ingredients at once and mixing them until the desired consistency is achieved. This type of mixer is suitable for small to medium-sized batches, making it a versatile choice for various industries. 

Additionally, batch mixers are typically portable, making them exceptionally versatile. There are several types of batch mixers and they can attach to a mixing vessel, such as a drum, IBC tote, open-top tank, or rolling mixer stand – which allows an operator to move the mixer from vessel to vessel. 

Although the popular choice, it might not be best suited for large-quantity applications. The better choice in this case is typically continuous mixers.

2. Continuous Mixers

Continuous mixers are designed to handle large quantities of materials continuously, making them ideal for high-volume production processes. Continuous mixing works on low energy, but still provides a high output. They work by feeding a steady stream of ingredients into the mixer while simultaneously discharging the mixed product.

Continuous mixers are unique, as they’re in-line mixers that are piped into part of the process. These mixers are typically between two or more tanks and can be placed upstream or downstream depending on the process requirements. Also, continuous mixers can be integrated into a monitoring system to allow for precise control over the blend. 

Some examples of continuous mixers include in-line rotor-stator mixers and static in-line mixers. paddle mixers, screw conveyors, and fluidized bed mixers.

3. High-Shear Mixers

High-shear mixers are used for emulsifying, dispersing, and homogenizing materials that are difficult to mix. They work by using high-speed rotating blades to create intense shearing forces that break down particles and blend them together. 

High-shear mixers are commonly used in pharmaceutical, cosmetic, and laboratory/research and development settings. They’re widely used in these industries since they can accommodate a wide range of viscosities and be made into benchtop scale, meaning they leave a small footprint for sitting on tabletops or counters.

Some examples of high-shear mixers include rotor-stator mixers, dispersers, and homogenizers.

4. Low-Shear Mixers

Low-shear mixers work by gently blending materials together without causing any damage or altering properties. These mixers are commonly used in the food industry for ingredients such as fruits and vegetables since they’re designed to mix delicately. 

5. Multi-Shaft Mixers

There are several types of multi-shaft mixers, including: 

• Dual Shaft Mixers
• Triple Shaft Mixers
• Planetary Mixers
• Reciprocating Mixers

While all of these mixers work similarly, they can each be customized to achieve whatever the customer’s process demands.

Factors to Consider When Selecting Industrial Mixers

When choosing an industrial mixer, the selection process depends on more than type alone. Here are some other important factors to consider:

Material Properties

The properties of the materials you're mixing play a significant role in determining which mixer to use. Factors including viscosity, density, and the presence of solids or liquids need to be taken into consideration. For example, high-shear mixers are ideal for materials of lower viscosity, while low-shear mixers are better suited for solid suspension.

Production Capacity

There are specific types of mixers best suited for your application depending on production capacity. While batch mixers are ideal for small to medium-sized production runs, continuous mixers typically handle larger volumes better. It's important to choose a mixer that can effectively handle your capacity needs while ensuring the quality of the mix.

Energy Efficiency

Especially in today's manufacturing world, energy efficiency is an essential factor to consider. Energy efficiency can significantly impact the operational costs of your manufacturing process, so selecting a mixer with good energy efficiency can be a cost-effective choice.

For example, some mixers, such as continuous mixers, operate on low energy but still provide high output -- which is ideal.

Mixer Versatility

Most likely, you'll want to use your mixer for more than one job. So, it's essential to have a mixer that offers versatility and accommodates different types of materials and mixing tasks.

Planetary mixers, for example, are well-known for their versatility and can handle a wide range of mixing jobs.

Industry Requirements

Mixing requirements and standards differ based on the industry. The pharmaceutical and food industries have strict hygiene and safety regulations to follow, while some industries, such as adhesives, may not have as difficult requirements. If you take the industry requirements into consideration upfront, you'll be able to find a mixer best suited for your specific project.

Technology and Innovation

As technology continues to evolve, newer types of mixers are being developed that offer improved efficiency, versatility, and other benefits. If you keep an eye out for the latest trends and innovations in industrial mixers, you may find one that better meets your needs.

Finding the Right Mixer for You

Keep in mind that the equipment you use for your mixing processes can make or break your production. With the right mixer, your process can enhance productivity, improve product quality, and reduce operational costs.

Take these factors into careful consideration before making your decision and reach out to a specialist with experience in your industry, like Mixer Direct.